Gelatin Manufacturing Plant – Complete Turnkey Solutions

Gem Pharma Machineries specializes in the design, fabrication, and integration of high-performance gelatin processing systems for pharmaceutical and nutraceutical manufacturing. We deliver turnkey gelatin processing suites, from raw material handling to the conditioned gelatin mass ready for encapsulation, all engineered for maximum yield, batch-to-batch consistency, and full cGMP compliance.

Hard Gelatin

Soft Gelatin

Modified release softgels

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Process Vessel specifications and Key Features

Our gelatin processing systems are built to the highest pharmaceutical standards. The typical equipment scope for a complete gelatin suite includes:

  • Gelatin Melting Vessel (Melter): Triple-layer (inner tank, jacket, insulation), vacuum-capable, with dual-motion agitator, wall scrapers, and a high-shear homogenizer for particle size reduction (to <5 microns).

  • Mobile Gelatin Holding/Receiver Tank: Insulated, heat-preserving, with a gentle airless mixer to prevent stratification before encapsulation.

  • Color/Additive Preparation Tank: A smaller jacketed vessel for slurry preparation, connected to the main system.

  • Vacuum System: A water-sealed or dry vacuum pump to deaerate the gelatin mass.

  • Transfer Pumps: Gentle positive displacement or diaphragm pumps designed for high-viscosity fluids without introducing air.

  • Heat-Traced Interconnecting Pipework: SS316L orbital-welded pipes with a hot water or thermal oil jacket, complete with zero dead-leg diaphragm valves.

  • Control Panel: A centralized PLC-HMI system for automated recipe management, temperature profiling, and batch reporting.

Process Vessel specifications and Key Features

Our gelatin processing systems are built to the highest pharmaceutical standards. The typical equipment scope for a complete gelatin suite includes:

  • Gelatin Melting Vessel (Melter): Triple-layer (inner tank, jacket, insulation), vacuum-capable, with dual-motion agitator, wall scrapers, and a high-shear homogenizer for particle size reduction (to <5 microns).

  • Mobile Gelatin Holding/Receiver Tank: Insulated, heat-preserving, with a gentle airless mixer to prevent stratification before encapsulation.

  • Color/Additive Preparation Tank: A smaller jacketed vessel for slurry preparation, connected to the main system.

  • Vacuum System: A water-sealed or dry vacuum pump to deaerate the gelatin mass.

  • Transfer Pumps: Gentle positive displacement or diaphragm pumps designed for high-viscosity fluids without introducing air.

  • Heat-Traced Interconnecting Pipework: SS316L orbital-welded pipes with a hot water or thermal oil jacket, complete with zero dead-leg diaphragm valves.

  • Control Panel: A centralized PLC-HMI system for automated recipe management, temperature profiling, and batch reporting.

Automation and Process Control

We construct every component with quality and regulatory compliance as the foundation:

  • Material of Construction: All product contact parts are SS316L (1.4404) with a mirror-polished surface finish of Ra ≤ 0.4 µm. Non-contact parts are SS304. All gaskets are FDA-compliant EPDM, silicone, or PTFE.

  • Welding: All pipework is fully orbital TIG-welded with 100% argon purging for smooth, crevice-free internal seams, ensuring complete drainability.

  • Vessel Design: Vessels are designed and fabricated as per ASME Sec VIII guidelines, with options for torispherical, hemispherical, or conical dish tops and bottoms.

  • Clean-in-Place (CIP): The entire system can be integrated with automated CIP, utilizing static and dynamic spray balls for complete cleaning coverage without manual intervention.

Applications

Our gelatin processing plants are designed to produce high-quality gelatin mass for a wide variety of encapsulation lines:

  • Soft Gelatin Capsules (Softgels): Preparing the gelatin ribbon for rotary die encapsulation of liquids, suspensions, and semi-solids.

  • Hard Gelatin Capsules: Producing the precise gelatin solution used in the dipping process for manufacturing empty two-piece hard capsules.

  • Veggie/Alternative Capsules: With minor adjustments, our systems can process non-animal gelatin alternatives like carrageenan or HPMC-based formulations.

Compliance & certifications

GMP compliant

FDA 21 CFR Part 11

ISO 9001

EU GMP Annex 11

ATEX / FLP rated

Gamp5

Turnkey Scope and Engineering Support

We understand that the gelatin processing unit is a subsystem of a larger facility. Our turnkey scope is designed for seamless integration:

  • Process flow design and 3D layout engineering to fit your cleanroom.


  • Complete utility planning (steam, hot water, chilled water, compressed air, purified water).


  • Fully assembled, piped, wired, and Factory Acceptance Tested (FAT) skids to minimize on-site installation time.


  • Complete validation package: URS, FDS, DQ, FAT, SAT, IQ, OQ, PQ protocols, and SOPs.

Build Your Next Pharma, Food and Cosmetic manufacturing plant with us

Talk to our engineering team. Get a concept layout and budgetary quote within 5 business days.

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